Industrial Flowmeters
Pitot tube deltaflow an engineering approach
systec Controls Meß- und Regeltechnik GmbH
Sebastian Fischer
Sales Manager
Industrial Flowmeters
Agenda
1.
Design your deltaflow
Select your deltaflow, deltaflow types, calculation software deltacalc, Mounting, Required
Parameters, dp-connection, opposite support
2.
Bidirectional Measurement
3.
Splitting Range
4.
How to handle polluted media - Air purging system LSP
5.
deltaflow for high-pressure applications – DF25HDD3
6.
How to calibrate your deltaflow
7.
Straight run requirements
8.
Using integrated temperature & pressure measurement
Industrial Flowmeters
Chapter 1 - Design your deltaflow
This chapter contains:
• What deltaflow types are available?
• What parameters do I have to know?
• What minimum dp should I have for reliable measurement?
• How can I handle low flows?
• How can I handle big measurement ranges (span)?
• How does a bi-directional measurement look like?
Industrial Flowmeters
Design your deltaflow – deltaflow series
DF8
DF12
DF25
DF25HDD3
DF25 Quicklok
DF44
Type
Pipe Size
Pressure
Remarks
DF8
1-25mm
0-690bar
Spool piece with integrated orifice
DF10
DN20-DN100
0-690bar
Basically replaced by DF12
DF12
DN20-DN100
0-160bar
DF25
DN65-DN2500
0-PN160 (PN250)
DF25 Quick-lock
DN65-DN2500
0-100bar
DF44
200mm-15m
0-100bar
DF25HDD3
60-690bar
0-690bar
Retractable
weld-in (high-pressure)
Industrial Flowmeters
Design your deltaflow – deltaflow types
What process connections / types are available?
Industrial Flowmeters
Design your deltaflow – deltaflow types
Flange-type
Cut-Ring Type
Industrial Flowmeters
Design your deltaflow – deltaflow types
Spool Piece
Weld-in (DF25HDD3)
Weld-in (DF12)
Industrial Flowmeters
Design your deltaflow – deltaflow types
DF25 Quick-lock system allows
mounting/extraction under
pressurized conditions (max.
100bar)
DF8 – spool piece (block) with
integrated orifice
Industrial Flowmeters
deltaflow types - Summary
DF8
DF12 DF25
Flange-stud
X
X
Cut-Ring
X
X
Weld-in
X
Quick-lock
Spool Piece
X
DF25
HDD3
DF44 Remarks
X
Max. PN250
(PN160 for steam)
Max. PN40
X
o.r.
X
X
X
Max. 100bar
X
max DN250 (other o.r.)
Note: Spool Pieces are available with welding ends or flanges
Industrial Flowmeters
Design your deltaflow – required parameters (1)
dp-connection
Stud (e.g. cut ring or flange)
Profile crosses whole diameter ->
length customized to application
Insulation
IT
• Internal Diameter ID
WT
• Wall thickness WT
• Thickness of isolation IT
ID
Profile
are required
Industrial Flowmeters
Design your deltaflow – required parameters (2)
Material
Designation
1.4571 (SS316Ti)
Stainless Steel, Standard
Material (>>90% of all
applications),
up to 500°C
1.4828
High-temperature
applications (up to 1040°C)
1.4539, Hastelloy
C4, Haynes Alloy
corrosive media
High-pressue
See seperate chapter
• In most cases neck and parts outside of the pipe can be made of
standard SS316 (1.4571) also when profile is made of special material
• Material of weld-in stud should be equal or similar to pipe material
Industrial Flowmeters
Design your deltaflow – required parameters (3)
Pipe Data
• Wall thickness
• Internal Diameter
• Pipe Material
• Orientation of Pipe (horizontal or vertical
Process
• Flow
• Temperature
• Pressure
Industrial Flowmeters
Calculate (design) your deltaflow – calculation software
deltacalc ?
..\..\..\..\Program Files\deltacalc 7\deltacalc7PRO.exe
Industrial Flowmeters
How can I connect my deltaflow with my dp-transmitter ?
Industrial Flowmeters
Design your deltaflow - Mounting of dp-transmitter
Direct Mounting
Remote Mounting
Industrial Flowmeters
dp-Connection - 3-way-manifold
direct
+ Easy setting of zero point by using by-pass
+ Shut-off of media (e.g. allows remove of transmitter)
+ high pressure / temperature (PN400)
- Smaller internal piping -> not recommended for wet gases
Industrial Flowmeters
dp-Connection – Ball Valves
Direct
Remote
+ Shut-off of media (e.g. allows remove of transmitter) possible
+ big opening -> recommended for wet/dirty gases (e.g. Biogas)
+ Available with threads, welding ends, oval adapters, fittings (ermeto,..)
- Limited concerning Temperature/Pressure (70bar at 35°C, 2 bar at 200°C)
Industrial Flowmeters
dp-Connection – Shut-off valves
Needle (shut-off) Valves (normally for
remote installation of transmitter)
• Double (see pic.) and single valves
available
•Available with welding ends, thread,
Ermeto, Swagelok. Customized
connections possible
+ Shut-off of media (e.g. allows remove of transmitter)
+ big opening
+ High pressure/temperature (PN400)
Industrial Flowmeters
dp-Connection – Miscellaneous
Fitting (e.g. Ermeto)
for remote mounting
Ball Valve with fitting (e.g.
Ermeto) for remote mounting
Welding Ends for
remote mounting
Oval Adapter (direct mounting)
(acc. to EN61518)
Industrial Flowmeters
dp-Connection – Miscellaneous (2)
Weather Protection Box
+ provides heating and protection for electrical equipment (transmitters)
+ Can be mounted remotley or direct on deltaflow‘s flange
Industrial Flowmeters
dp-Connection – Summary
• Various possibilities of connections of dp-transmitters are available
• Possibility to shut-off connection to media (valves) is recommended
• If not specified by customer we recommend 3-way-manifold or ball valve
(wet / dirty gases) for standard applications
• When using high-pressure equipment double valves are recommended
Industrial Flowmeters
How should I mount my deltaflow?
Industrial Flowmeters
Mounting – Liquid Service
• Mounting should allow gas bubbles to vent off
• When installed sidewards probe should be slightly slanted
(-3…0°)
Industrial Flowmeters
Mounting – Gas Service
• Mounting should allow condensate to drain back into pipe
(Otherwise condensate might accumulate in internal piping
and generate water column (which generates faulty dp))
• When installed sidewards probe should be slightly slanted
(0..3°)
Industrial Flowmeters
Mounting – Steam Service
• Condensate is used to transmit dp to transmitter
• Mounting should allow excessive condensate to drain back
into pipe
• When installed sidewards probe should be slightly slanted
(0..3°)
Industrial Flowmeters
Design your deltaflow – Required dp
deltaflow requires a minimum differential pressure to ensure
reliable measurement:
As rule of thumb you should have at least:
• Gases / Liquids: >0.2mbar @ Qmin
• Steam: >5mbar (steam applications are more sensitive against
misinstallation than gas / liquids) @ Qmin
dp‘s can be calculated for each application by using deltacalc
software
Industrial Flowmeters
Design your deltaflow – required dp
How can I handle low flows?
• Sometimes velocity is too low to provide sufficient dp values
• Spool Pieces with reduction can be used to speed up media
Reduction
Widening (e.g.
DN65/DN100
(e.g. DN100/DN65)
By using spool pieces with
reduction deltaflow can serve also
typical low flow applications (e.g.
Biogas)
Industrial Flowmeters
Design your deltaflow – opposite support
What‘s about the mechanical stability of deltaflow?
When do I need an opposite support ?
Industrial Flowmeters
Opposite Support - Background
 Probe has a specific resonance frequency
(RF) depending on length and width of probe
 Flow generates Vortex („turbulence“) with a
specific frequency (VF) at probe depending
on velocity and width of probe („probe is
stimulated“)
[RF and VF are mentioned at deltacalc calculation protocol]
 If Vortex frequency = resonance frequency
(or multiple) probe might resonate and might
break!
Vortex
 To ensure mechanical stability an opposite
support might be required
Industrial Flowmeters
Frequency calculation without opposite support
Application: Steam, DN200, 7bar, 200°C, various flows, without opposite support
v=7.73m/s
v=24.58m/s
v=61.46m/s
RF
VF
SF
VF
SF
VF
SF
DF25
248.9
70,2
3,55
234,1
1,06
585,3
0,43
DF32
264.5
43,8
6,04
145,9
1,81
364,7
0,73
DF44
383.3
33,5
11,44
111,7
3,43
279,4
1,37
RF = Resonance Frequency of Probe / VF=Vortex Frequency
Saftey Factor SF = RF/VF
SF should be >= 1.3 to ensure mechanical stability
Industrial Flowmeters
Frequency calculation with opposite support
Application: Steam, DN200, 7bar, 200°C, various flows, with opposite support
v=7.73m/s
v=24.58m/s
v=61.46m/s
RF
VF
SF
VF
SF
VF
SF
DF25
995,8
70,2
14,19
234,1
4,25
585,3
1,7
DF32
1058,0
43,8
24,16
145,9
7,25
364,7
2,9
DF44
1535,2
33,5
45,83
111,7
13,74
279,4
5,49
Opposite Support quadruples Resonance Frequency and Saftey!
The bigger the profile the higher the resonance frequency
Industrial Flowmeters
Opposite Support – Examples
DF25 prepared for use with (upper) and
without (lower) opposite support
High-pressure probe with
opposite support
Industrial Flowmeters
Opposite Support – Summary / Design Rules
Opposite Support Required if:
• Pipe Size >= DN1000
• dp >= 20mbar and RF/VF <= 1.3
• High-pressure probe
Check (if required or not) is done automatically by deltacalc (except
because of size!)
Industrial Flowmeters
Chapter 2 – Splitting Range Measurement
How can I handle big measurement ranges?
Industrial Flowmeters
Splitting range
•
deltaflow offers a span of typically 1 to 7..10
•
1 to 10 in flow means 1 to 100 (!) in dp
How does that influence my measurement?
Example:
dp_min = 2mbar / dp_max = 240mbar
span dp-transmitter: 250mbar, uncertainty 0.1%
(=0.25mbar)
0.25mbar at 2mbar means relative uncertainty of 12.5%
With splitting range. e.g:
1. Transmitter: 0…20mbar
2. Transmitter: 20…240mbar
Industrial Flowmeters
Design your deltaflow – splitting range
How can I realize a splitting range measurement?
• You need two (or more) (stacked) transmitters
• You need evaluation unit (e.g. flowcom or PCS)
which decides which transmitter should be used
(depending on dp)
Connectors („T-bone“)
Industrial Flowmeters
Splitting range - summary
• With splitting range up to 4 dp-transmitters can be used
• Span of 1..30 and more can be realized
(pay attention to mechanical stability)
Industrial Flowmeters
Chapter 3 – Bi-directional Measurement
Industrial Flowmeters
Bi-directional measurement
• Thanks to symetrical profile deltaflow
can measure bidirectional
• Each direction requires it‘s own transm
• Flowcom (or PCS) controls measurem
Back Flow (splitting
range)
Flow (splitting
range)
Industrial Flowmeters
Chapter 4 – Air purging
When do I need an air purging system (LSP)
Industrial Flowmeters
Air purging system LSP
• Highly Polluted media might clog deltaflow‘s dp-tappings
• When dust-load >=50mg/m3 automatical cleaning is
required
• systec offers automatic air purging system LSP for
periodical cleaning
• LSP blows pressurized air into deltaflow pressure
chambers
Industrial Flowmeters
Air purging system LSP - Principle
Valves: When purging
connection to dptransmitter is closed and
connection to pressurized
air is open
Connections
for dp-impulse
pipes (Ermeto,
others on
request)
Connection for
pressurized air
(max. 6bar)
dp-transmitter can be mounted
directly on LSP by using
mounting plate
Purging is controlled by SPS.
Frequency of purging as well as
length of purging can be set by
user
Industrial Flowmeters
Air purging system LSP - Example
deltaflow DF50 (old
style), flange type
Shut-off (ball valves)
LSP with mounted dptransmitter
Connected by impulse
piping
Industrial Flowmeters
Air purging system LSP - Summary
• With LSP measurements at high degrees of pollution (up to
200 g/m3 (!)) become possible
• During purging dp is hydraulically locked -> no lost of dpsignal during purging
• Option „Signal holding“ available. Here, last value of dp
before purging is holded electronically by SPS
• Direct mounting of dp-transmitter possible (on top of LSP)
• Pressurized Air required on site (max. 6 bar)
• Impulse piping required (LSP - deltaflow)
Industrial Flowmeters
Chapter 5 – deltaflow for high-pressure applications
When do I need a high-pressure probe and what‘s about it ?
Industrial Flowmeters
High pressure probe
When do I need high pressure probe?
• Limits for standard DF25: PN160 (steam), PN250 (Liquids)
Finally, it has to be determined by customer, but there are
indications when to use high-pressure probe:
• When weld-in probe is required (e.g. sealings are not
accepted)
• When pipe is made of high grade material (e.g. P91, 10CrMo
9 10))
Industrial Flowmeters
High pressure probe
For high pressure applications a special version of the DF25
(DF25HDD3) is available
Condensate Pots
(for steam only)
Weld-in part
(„neck)
Profile
• Profile made of massive block (no
welding seams)
• Material of Profile: 1.4828
• Materials of weld-in parts:
Double valves 16Mo3, 10CrMo 9 10, P91
• Material of valves:
16Mo3, 10CrMo 9 10
• opposite support always required
Industrial Flowmeters
High pressure probe - Examples
- Steam, 535°C, 190bar
- spool piece
- Profile: 1.4828
- Weld-in part: P91
- Condensate Pots: P91
- Steam, 540°C, 100bar
- Profile: 1.4828
- Weld-in part: 10 CrMo9 10
- Condensate Pots:
10 CroMo 9 10 (=1.7380)
Industrial Flowmeters
High pressure probe – Required certificates / testings
Requirements are regulated by PED97/23/EG
16 Mo 3
(1.5415)
13CroMo44
(1.7335)
10CrMo9 10
(1.7380/1.7383)
X20CrMoV12 1
(1.4922)
X-Ray
TÜV acceptance
test (dye penetration,
P91
(1.4903)
X
x
x
x
x
X
x
x
x
x
x
x
x
x
hardness test, material
identification check)
Heat
treatment
Documentation incl.
3.2 certificate
x
Industrial Flowmeters
Chapter 6 – Calibration
Industrial Flowmeters
Calibration
qm 
1



4
d ² 2  dp  
Formula for flow calculation
• During calibration flow, dp (at deltaflow), p, T are measured at
different points
• Corrected Blockage Factor Zeta is extracted
• Corrected Zeta will be then used for your appliaction
-> Improved accuracy (0.4%)
• Calibration can be done at PtB or at systec
• Spool Piece always required
• PtB or systec issue calibration certificate
Industrial Flowmeters
Factory Certificate
PtB Certificate
Industrial Flowmeters
Chapter 7 - Straight run requirements
What is the best mounting position for my deltaflow?
Industrial Flowmeters
Straight run requirements
Industrial Flowmeters
Straight run requirements - ImproveIT
•ImproveIT is a data base which offers
calibration factors for typical obstacles
in inlet (curves)
• Factors are provided by systec on
request
• Factors can be put into deltacalc
Industrial Flowmeters
Chapter 8 – Integrated pressure and temperature measurement
Why could p/T-compensation improve the accuracy?
How does it look like?
Industrial Flowmeters
Integrated pressure/temperature measurement - background
qm 
1



4
d ² 2  dp  
Density, depends on
pressure (p) and
Temperature (T)
• If pressure and/or temperature change, density also changes
• Density influences flow (e.g. T +10% -> density +10% -> q +srt(10%)=3.16%
• To compensate influence, p and/or T should be measured in order to calculate
correct density (flowcom / multi variable transmitter)
• Only recommended/required when p and/or T fluctuate
Industrial Flowmeters
Flowcomputer flowcom
• p&T compensation + Mass flow calculation
• Heat transfer measurement
• Data Logger + Display
• Easy handling (on-site with buttons)
Industrial Flowmeters
Integrated pressure/temperature measurement
Cable Box
Integrated PT100
Presseure measurement
(here: Steam Service)
- Can be removed under pressurized
conditions
- 0…400 (600°C)
- direct PT100 or 4…20mA (with transmitter)
- Can be removed under pressurized
Conditions (when having valve)
- direct PT100 or 4…20mA
Industrial Flowmeters
Integrated pressure/temperature measurement - Examples
DF44 with preparation for external
pressure transmitter (supplied by
customer)
(here: Liquid Service)
DF12 with spool piece, integrated
temperature measurement
(Gas Service)
Industrial Flowmeters
Integrated pressure/temperature measurement - Examples
DF10 with integrated
DF8 with preparation for
temperature (Gas Service) pressure measurement
(Gas Service)
DF8 with preparation for
pressure measurement
(Steam Service)
Industrial Flowmeters
Integrated pressure/temperature measurement
Model
Integrated
pressure
Integrated
Temperature
DF8
X
X
Integrated in
spool piece
DF10
X
X
Integrated in
spool piece
DF12
(x)
(x)
Only with
spool piece
DF25
X
X
X
X
DF25HDD3
DF44
Industrial Flowmeters
References
• deltaflow Data Sheets
• deltacalc calculation software
• deltaflow manual
• flowcom manual
• LSP manual